JP5689688B2 - Mold and manufacturing method thereof - Google Patents

Description

  The present invention includes a working part of a tool and a first part manufactured from steel, a second part including a body component of the tool and manufactured from gray cast iron. And a mold for composite casting of an integral casting tool in which at least one coupling region exists between steel and gray cast iron.

  The present invention includes a working part of a tool and includes at least a first part manufactured from steel and a second part including a main body member of the tool and manufactured from gray cast iron. It also relates to a method of manufacturing a mold for composite casting of a monolithic casting tool in which there is at least one coupling region with cast iron.

  Traditionally, in the manufacture of tools for processing sheet metal, such as cutting, bending, or other forming, it is often customary to individually manufacture a gray cast iron tool body. Conventionally, a processing member that performs an actual work intended for the tool is attached to the tool body. The manufacture of the tool body is performed by casting, and after casting, a heat treatment of the tool body is often required. After this, the tool body is fixed in the machine as well as to realize the seating, guide stub shafts, and bolt holes to fix them, which are required for the workpiece (s) of the tool Machine tool machining continues.

  In the production of the workpiece (one or more) that the tool should have, the starting point is often a rod-like material, the workpiece is machined to the correct shape, holes for fixing bolts, guide stub shafts, etc. are machined . This is usually followed by heat treatment, after which further machining, for example polishing, is performed.

  Producing tools in the manner outlined above is extremely time consuming and expensive, and is therefore often a determinant of the time consumption required for new production of different products.

  International Application Publication No. 03/0418951 discloses an integral composite cast tool (the tool has different material composition in different parts of the tool) and its manufacturing method. However, the production according to this publication encounters a major problem in certain aspects (for example, the formation of the mold model to be employed).

WO03 / 0418951A1

  The object of the present invention is to design the mold shown at the beginning so as to solve the problems inherent in the prior art. In particular, it is an object of the present invention to design a mold so that it can be manufactured at low cost and with high accuracy. It is a further object of the present invention to design a mold so that materials having different coefficients of thermal expansion can be cast without difficulty in a single and the same mold.

  As for the method, the present invention has similar objectives as described above.

The mold includes at least a first model part (first type cavity forming part: model section) corresponding to the first part and at least a second model part (second type cavity forming part) corresponding to the second part. The mold is characterized in that it is horizontal and flat at the position of use of the mold and includes the first mold part contacting the second mold part along at least one contact surface representing the bonding region in the mold. If possible, the object underlying the present invention will be achieved.
In particular, a plurality of first portions defining a workpiece of a tool made from steel and a second portion defining a body member of the tool made from gray cast iron, between the steel and gray cast iron A mold for composite casting of an integral casting tool having a plurality of coupling regions, wherein a plurality of first mold model portions respectively corresponding to the plurality of first portions, and at least corresponding to the second portions. Including a second type model part, each of the plurality of first type model parts and the second type model part being horizontal and flat at the use position of the mold, and representing the plurality of coupling regions A mold that contacts along a plurality of contact surfaces and is designed to be on a common plane is desirable.

For the method, the first type model part is manufactured in association with the first part, the second type model part is manufactured in association with the second part, and the first type model part and the second type model part , Provided with at least one flat contact surface (along the contact surface, the first model model part and the second model model part contact each other), and the mold is brought into a final form using a mold material. If the mold is characterized such that the contact surface is positioned at a horizontal position (assuming that it is the coupling area) at the mold's molding position and the first mold model is at the lowest position The objectives of the present invention will be achieved.
In particular, a plurality of first portions defining a workpiece of a tool made from steel and a second portion defining a body member of the tool made from gray cast iron, between the steel and gray cast iron A method of manufacturing a mold for composite casting of an integral casting tool having a plurality of coupling regions, the plurality of first mold model portions respectively corresponding to the plurality of first portions, and the second portion A plurality of first type model parts corresponding to each other, each of the plurality of first type model parts and the second type model part being horizontal and flat at a use position of the mold; It is desirable to have a method in which the mold is designed to contact along a plurality of contact surfaces representing a region and the plurality of contact surfaces lie on a common plane.
The following preferred embodiments are also included in the present invention.
(Form 1)
A first part made of steel and made of steel; and a second part made of gray cast iron and made of steel and between the steel and gray cast iron. A mold for compound casting of an integral casting tool having at least one coupling region
The mold includes at least one first model part (model section) corresponding to the first part and at least one second model part corresponding to the second part;
The first mold model part is horizontal and flat at the use position of the mold, and is in contact with the second model model part along at least one contact location representing a bonding region in the mold;
A mold characterized by.
(Form 2)
The mold according to aspect 1, wherein the first mold part [sic, mold model part] is designed to have a larger shrinkage margin than the second mold model part.
(Form 3)
The mold according to aspect 2, wherein the first-type model portion and the second-type model portion that meet each other on the contact surface have an inclined transition region in order to avoid a step-like transition on the contact surface. .
(Form 4)
Any one of Embodiments 1 to 3, wherein the first mold part [sic, first type model part] is mutually coupled to an adjacent portion of the second mold part [sic, second type model part]. The mold according to 1.
(Form 5)
Both the first mold model part and the second model model part are located in a common mold frame;
The first model part is located at the lowest position in the use position of the mold;
The mold according to any one of Forms 1 to 4, wherein
(Form 6)
The first mold model part is located in a lower mold frame at a use position of the mold;
The second mold model part is located in the upper mold frame at the use position of the mold;
The dividing surface between these mold frames is horizontal and includes a contact surface;
The mold according to any one of Forms 1 to 3, wherein
(Form 7)
7. The mold according to aspect 6, wherein the first mold model part includes one or more mold cores having a surface exposed at at least a part of the contact surface and having a surface coinciding with the contact surface.
(Form 8)
The mold has two or more first model parts and two or more contact surfaces;
All contact surfaces must be in a common plane
The mold according to any one of forms 1 to 7, which is characterized by the following.
(Form 9)
A first part made of steel and made of steel; and a second part made of gray cast iron and made of steel and between the steel and gray cast iron. A method for producing a mold for composite casting of an integral casting tool wherein at least one coupling region is present in
The first model part is manufactured in association with the first part;
A second model part is manufactured in association with the second part;
The first type model part and the second type model part have at least one flat contact surface, and the first type model part and the second type model part contact each other along the contact surface. about,
The mold is finished with a mold material, the contact surface is arranged in a horizontal position at the casting position of the mold to become a coupling region, and the first mold model part is arranged in the lowest position;
A method characterized by.
(Form 10)
10. The method of embodiment 9, wherein the first mold model part is designed to have a larger shrinkage margin than the second mold model part.
(Form 11)
The method according to embodiment 9 or 10, wherein the first mold model portion is interconnected with the second mold model portion before the mold reaches the final shape.
(Form 12)
The method according to any one of Embodiments 9 to 11, wherein the first model model part and the second model model part are installed in a common mold frame.
(Form 13)
The first mold model portion is installed in a first mold frame;
The second model part is installed in a second mold frame;
The dividing surface between them coincides with the contact surface,
The method according to claim 9 or 10, wherein
(Form 14)
At least one mold core is installed in the first model part,
The mold core is formed to have a surface that coincides with at least a portion of the contact surface;
A method according to aspect 12, characterized by:

The invention will now be described in more detail with reference to the accompanying drawings. The attached drawings are as follows.
FIG. 1 is a simplified cross-sectional view of a mold according to an embodiment of the present invention. FIG. 2 is a detailed cross-sectional view of a part of a mold model (model) for manufacturing a mold according to an embodiment of the present invention. FIG. 3 shows a final mold model according to FIG.

  In FIG. 1 showing a cross section of a mold according to the present invention, reference numeral 1 relates to a molding box or flask, reference numeral 2 relates to a first section (first mold model portion) of the mold model, and reference numeral 3 Is related to the second section of the mold model (second model part). Both sections of the mold model are made from a material that can be destroyed in the casting operation, for example, polystyrene foam.

  According to the present invention, in some alternative special cases, it is possible to produce a mold model or a part thereof even with a material that cannot be destroyed during casting. In that case, such a mold model must be removed from the mold before performing the casting. In other embodiments, for example when a mold core is employed, it may be advantageous in some cases to remove a model or part thereof that can be destroyed during casting before performing the casting. possible.

  The first section 2 of the mold model shall be for steel casting, while the second section of the mold model shall be for gray iron casting. Therefore, a coupling region is formed between these two materials at the contact surface 4 represented by the broken line in FIG. If the invention is implemented correctly, such a bonding area has a thickness of 1 to 2.5 mm, where both casting materials are mixed somewhat.

  For steel casting, there is a gate or sprue 5, and at least a part of the gate or sprue 5 is the first model part (cavity forming part) at the position where the mold shown in FIG. 1 is used. ) Connected to a pouring system located below 2 and designed to pour up and down. In this use position, the contact surface 4 is horizontal.

  Although only a single first section 2 model is shown in FIG. 1, a plurality of such first sections (in a tool cast in a mold) in a single and identical mold frame 1. It should be emphasized that a workpiece may be located). The workpiece may be designed for sheet metal cutting, hole making, bending or other forming. In FIG. 1, for example, a cutting blade is denoted by reference numeral 7.

  The first section 2 of the mold [sic, model] has at its end facing the contact surface 4 a wall portion 8 of substantially uniform thickness over the entire area. Similarly, the second section 3 of the model part corresponds to the wall part 8 in terms of shape and thickness in the region of the contact surface 4, but with a certain difference, as will be described in detail below. 9

  In FIG. 1, the contact surface 4 is parallel to the lower edge 10 of the mold frame 1, which means that if the mold frame is placed on a flat and horizontal object (eg, floor), the contact surface 4 Ensure that face 4 will be level.

  In the production of the mold according to FIG. 1, the upper part 11 relative to the mold frame is first removed and the mold frame 1 is flat and horizontal with the upper end 12 turned over so that it faces downwards. Installed on an object. Thereafter, the entire model composed of one or more first sections 2 and one second section 3 is placed on the object on which the upper end 12 of the mold frame 1 is placed. However, this presupposes that the contact surface 4 is parallel to the upper surface 13 of the second model part 3. What is important is that the contact surface 4 is horizontal at the casting position of the mold and parallel to the lower end 10 of the mold frame in the mold shown in FIG.

  It may also be appropriate to connect the second model part 3 and the first model part 2 (one or more) together so that they form a unit that is easy to handle together.

  Thereafter, the mold frame 1 is filled with mold sand of appropriate quality, and this mold sand is similar around the second model model part 3 and around the first model model part 2 (one or more). It should be emphasized that it is not necessary to have quality. When the mold frame 1 is filled with mold sand by such means and is compacted and ready to be installed, the mold frame 1 is turned over to the casting position. Since the object on which the mold frame is installed is also horizontal, it is guaranteed that the contact surface 4 is horizontal. Thereafter, the upper portion (lid) 11 is placed on the mold frame 1, and the mold is completed by attaching the gates 5 and 6.

  If the second section 3 of the model does not have its upper side 13 (in FIG. 1) parallel to the contact surface 4, in the final form of the mold, the mold frame 1 is consequently placed on a horizontal object. The second model part 3 must be adjusted with a wedge until it has the correct inclination to compensate for non-parallelism between the contact surface 4 and the upper surface 13 so that the contact surface 4 is always horizontal when Don't be.

  In composite casting of two different casting materials, they often have different coefficients of thermal expansion and can cause problems in the bonding area of the contact surface 4 between the sections 2 and 3 of the mold model. In the example for this case, the steel is cast first in the first section 2 of the mold model and is partially allowed to cool before the cast gray iron is cast in the second section 3 of the model. Of the two materials, steel exhibits a coefficient of thermal expansion that is significantly greater than that of gray cast iron. For this reason, the first section 2 (one or more) of the model is designed with a contraction margin that is larger than the contraction margin applied to the second section 3 of the model. This relationship is illustrated in FIG. 2 which shows the part of the first section 2 and the part of the second section 3 of the model with both walls 8 and 9 on both sides of the contact surface 4. It is assumed that the mold model extends to the left of the virtual line 14.

  Since the cast steel is expected to shrink in the left direction, it will be clear from FIG. 2 that the wall portion 8 is not in a straight line with the wall portion 9 and is shifted to the right in FIG. .

  It will be apparent from FIG. 3 that the mold model parts 2 and 3 are chamfered by the slope 15 along the wall portion 9 and the slope 16 along the wall portion 8. By such means, the transition (or transition) region between the wall portions 8 and 9, ie the bonding region located at the contact surface 4 between steel and gray iron, will be smoother in the transition.

  In order to hold the two mold parts 2 and 3 together, they can be glued together, or the seam can be fastened together by tape or the like.

  In the above-described embodiment, both of the model model portions 2 and 3 are placed in a single and the same mold frame 1.

  In another version, the mold frame 1 is divided into a lower mold frame and an upper mold frame, in which only the first section 2 (one or more) of the model is stored, On the other hand, the upper mold frame is used for the second section 3 of the model.

  Therefore, when using a divided mold frame, the first section 2 of the model is placed on a flat object and inside the lower mold frame, after which mold sand is added, packed and set Is done. Thereafter, the lower mold frame is turned upside down and the upper mold frame is placed thereon. Thereafter, the second section 3 of the model is placed in the correct position on the lower mold frame and the contact surface 4 and the mold reaches its final form.

  In other embodiments, during casting, a mold core that provides a cavity in the steel when the steel is cast can be placed under the contact surface 4. After opening the mold, that is, after removing the upper mold frame, the core can be removed and the cast steel can be inspected by casting the cast steel before the lower mold frame is placed and secured again.

1 Mold frame 2 First section of the mold model (first mold model part)
3 Second section of mold model (second model part)
4 Contact surface 5 Gate or sprue 6 Gate or sprue 7 Cutting blade 8 Wall portion 9 of the first section 2 Wall portion 10 of the second section 3 Lower end 11 of the mold frame 1 Upper portion 12 relative to the mold frame 1 Mold frame 1 Upper end 13 of the second model part 3 Upper surface 14 Virtual line 15 Slope 16 along the wall portion 9 Slope along the wall portion 8

Claims (14)

A plurality of first portions defining a shape of a workpiece of a tool manufactured from steel and a second portion defining a shape of a body member of the tool manufactured from gray cast iron, the steel and gray cast iron A mold for composite casting of a one-piece casting tool having a plurality of coupling regions therebetween,
A plurality of first type model parts respectively corresponding to the plurality of first parts; and at least one second type model part corresponding to the second parts;
Each of the plurality of first type model parts and the second type model part are horizontal and flat at the use position of the mold, and are in contact with each other along a plurality of contact surfaces representing the plurality of coupling regions; and ,
A mold designed such that the plurality of contact surfaces lie on a common plane.   The mold according to claim 1, wherein the plurality of first type model parts are designed to have a larger shrinkage margin than the second type model parts.   3. The mold according to claim 1, wherein each of the plurality of first-type model portions and second-type model portions has a contact surface that is chamfered in an inclined shape, and is designed to be mutually coupled at the contact surface.   The mold according to any one of claims 1 to 3, wherein the plurality of first type model parts are designed to be mutually coupled to adjacent parts of the second type model part. All of the plurality of first type model parts and second type model parts are arranged in a common mold frame,
The mold according to any one of claims 1 to 4, wherein the plurality of first type model parts are designed to be disposed at a position lower than the second type model part. Having one or more mold cores in the first model part,
The mold according to any one of claims 1 to 5, wherein the mold is designed such that a surface of the one or more mold cores is exposed at at least one position of the plurality of contact surfaces.   The mold according to any one of claims 1 to 6, which is designed so that all of the plurality of contact surfaces exist on a common plane. A plurality of first portions defining a shape of a workpiece of a tool manufactured from steel and a second portion defining a shape of a body member of the tool manufactured from gray cast iron, the steel and gray cast iron A method of manufacturing a mold for composite casting of a monolithic casting tool having a plurality of coupling regions therebetween,
A plurality of first type model parts respectively corresponding to the plurality of first parts; and at least one second type model part corresponding to the second parts;
Each of the plurality of first type model parts and the second type model part are horizontal and flat at the use position of the mold, and are in contact with each other along a plurality of contact surfaces representing the plurality of coupling regions; and ,
The method is characterized in that the mold is designed such that the contact surfaces are on a common plane.   9. The method of claim 8, wherein the mold is designed such that the plurality of first type model parts have a larger shrinkage margin than the second type model parts. The plurality of first-type model portions and second-type model portions each have a contact surface that is chamfered in an inclined manner, and are designed to be mutually coupled at the contact surface. The method described.   11. The mold according to claim 8, wherein the mold is designed such that the plurality of first type model parts are mutually coupled to adjacent portions of the second type model part. Method. All of the plurality of first type model parts and second type model parts are arranged in a common mold frame,
The mold according to any one of claims 8 to 11, wherein the mold is designed so that the plurality of first type model parts are arranged at a position lower than the second type model part. The method described. Having one or more mold cores in the first model part,
The mold according to any one of claims 8 to 12, wherein the mold is designed such that a surface of the one or more mold cores is exposed at at least one position of the plurality of contact surfaces. Method.   The method according to claim 8, wherein the mold is designed such that all of the plurality of contact surfaces are on a common plane.

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